Knock down bed foundation

ABSTRACT

A knock down bed foundation includes a pair of side rails, a pair of end rails, a center rail and a set of slats. Each end rail extends perpendicularly between a corresponding ends of each side rails and the center rail extends perpendicularly between each end rail. The slats are spaced apart between the end rails and extend perpendicularly between each side rails over the center rail. Corner clips secure the abutting portions of the side rails and end rails together.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Patent Application No. 62/126,879, filed Mar. 2, 2015, which is incorporated herein by reference in its entirety.

BACKGROUND

Mattresses are conventionally supported by a foundation such as a box spring or metallic springs. Beds, including but not limited to king and queen size beds, require foundations which are heavy, awkward to handle and may not fit through some doorways. Knock down foundations for beds are comprised of separate components which are assembled or disassembled on site for to aid in transport or disposal. Such foundations are typically constructed from wood and assembled using fasteners requiring tools.

BRIEF SUMMARY

According to one embodiment of the invention, a knock down bed foundation includes a pair of side rails, a pair of end rails extending perpendicularly between the side rails to form corners therewith, a center rail extending perpendicularly between the end rails, a plurality of spaced apart slats extending perpendicularly between the side rails over the center rail, and a plurality of corner clips securing the side rails and end rails together at the corners.

According to one embodiment of the invention, a kit for knock down bed foundation includes a pair of side rails, a pair of end rails configured to extend perpendicularly between the side rails to form corners therewith, a center rail configured to extend perpendicularly between the end rails, a plurality of slats configured to extend perpendicularly between the side rails over the center rail, and a plurality of corner clips configured to secure the side rails and end rails together at the corners, when the side rails and end rails are positioned perpendicularly with one another.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is an exploded perspective view of a knock down bed foundation according to an embodiment of the invention.

FIG. 2 is a perspective view of the assembled knock down bed foundation of FIG. 1.

FIG. 3A is an exploded view of the knock down bed foundation corner assembly according to an embodiment of the invention.

FIG. 3B is an assembled perspective view of the knock down bed foundation corner assembly of FIG. 3A.

FIG. 4 is a perspective view of a knock down bed foundation having a cover according to an embodiment of the invention.

DETAILED DESCRIPTION

Turning now to the drawings and to FIG. 1 in particular, there is shown an exploded view of a knock down bed foundation 10 according to an embodiment of the invention. The knock down bed foundation 10 includes a pair of side rails 20, a pair of end rails 40, a center rail 60, a set of slats 80, push pin connectors 100 and corner clips 120. The side rails 20, end rails 40, center rail 60 and set of slats 80 may be formed from a variety of materials including, but not limited to, manufactured lumber, plywood, manufactured wood product or plastic. The push pin connectors 100 and corner clips 120 may also be made from a variety of materials including, but not limited to, metals, plastics or composites.

The side and end rails 20, 40 together define a generally rectilinear frame, with the rails 20, 40 being joined or connected at corners for the frame by the corner clips 120. The corners of the frame may be formed by abutting the side and end rails 20, 40 together in a simple butt joint or by joining the rails 20, 40 in another fashion. For example, as described in further detail below, the terminal ends of the side and/or end rails 20, 40 forming the corners of the illustrated foundation 100 can be rabbeted to further stabilize the corners of the foundation 100. Other joinery techniques can be employed as well.

The side rails 20 include an upper horizontal side rail member 22 having a set of pin apertures 23 disposed therein and a lower horizontal side rail member 24 connected together by vertical side rail members, which may include vertical side rail posts 26 and/or corner blocks 28. A horizontal slat retaining member 25 having slat dado notches 27 is attached to the top side of the upper horizontal side rail member 22. When viewed from above, the dado notches 27 have three sides. Side corner blocks 28 are disposed at opposing ends of the side rails 20 between the upper and lower horizontal side rail members 22, 24. The side corner blocks 28 include a corner recess 30 at the edge therein, and a groove 32 formed therein. The groove 32 can run the full length of the block 28, or some sub-length of the block 28 as shown in the illustrated embodiment.

The end rails 40 include an upper horizontal end rail member 42 and lower horizontal end rail member 44 connected together by vertical side rail members, which may include vertical end rail posts 46 and/or corner blocks 50. Openings 48 are formed in the center of the side rails 40 between adjacent vertical end rail posts 46. End corner blocks 50 are disposed at opposing ends of the end rails 40 between the upper and lower horizontal end rail members 42, 44. The end corner blocks 50 also include a groove 52 formed therein similar the side corner blocks 28 and are dimensions to be received in the corner recess 30 in the edge of the side corner blocks 28 to form the rabbeted corner of the foundation 100. The groove 52 can run the full length of the block 50, or some sub-length of the block 50 as shown in the illustrated embodiment.

The center rail 60 includes an upper horizontal center rail member 62 and lower horizontal center rail member 64 connected together by vertical center rail members, which may include vertical center rail posts 66 and/or end blocks 68. Center rail end blocks 68 are disposed at opposing ends of the center rail 60 between the upper and lower horizontal center rail members 62, 64. A protruding portion 70 of the center rail end blocks 68 extends past the upper and lower horizontal center rail members 62, 64 and is dimensioned to be received in one of the openings 48 formed in the center of the side rails 40.

While only one center rail 60 is shown herein, some embodiments of the foundation 100 may employ more than one center rails 60. For example, a king-size foundation may include two center rails 60, while a queen-, full- or twin-size foundation may include one center rail 60 are shown. Some smaller foundations may eliminate the center rail altogether.

The set of slats 80 are dimensioned to extend between the horizontal slat retaining members 25 and to be received in the slat dado notches 27. The set of slats 80 include a pin aperture 82 positioned to align with the pin apertures 23 of the upper horizontal side rail member 22 when the set of slats 80 are received in the slat dado notches 27. A set of push pin connectors 100 are provided to secure the set of slats 80 to the upper horizontal side rail members 22 by being inserted through the pin apertures 23, 82. The push pin connectors 100 may have a shaft dimensioned to provide a friction fit with the pin apertures 23, 82 and a flange to rest on top of the slats 80. The push pin connectors 100 may also have a directionally biased structure disposed on the shaft to discourage removal of the push pin connectors 100 from the pin apertures 23, 82

A set of corner clips 120 are provided to secure abutting side rails 20 and end rails 40 together. The corner clips 120 form an L-shape or V-shape and are dimensions to be received in the grooves 32, 52 of the corner blocks 28, 50. The corner clips 120 provide a tensioning force to secure the corner blocks 28, 50 together as will be discussed in further detail below.

To assemble the knock down bed foundation, as seen in FIG. 2, the center rail 60 is positioned between the end rails 40 such that the protruding portion 70 of the end blocks 68 is received in the openings 48 of the end rails 40. The side rails 20 are then positioned on both sides of the side rails 40, extending therebetween. The end corner blocks 50 are received in the corner recess 30 of the side corner blocks 28 and the corner clips 120 are inserted into the grooves 32, 52 of abutting corner blocks 28, 50 to secure abutting side rails 20 and end rails 40 together. The set of slats 80 are then positioned to extend between the side rails 20 such that they are received in the slat dado notches 27 of the horizontal slat retaining member 25. Push pin connectors 100 are inserted through the slats 80 into the side rails 20 to secure the set of slats 80 to the side rails 20.

Now referring to FIGS. 3A and 3B, it can be seen that the corner clips 120 have a general L-shape or V-shape. A bend 122 in the corner clips 120 defines the boundary between a first clip portion or leg 124 and a second clip portion or leg 126. The first leg 124 can have a length L1 and the second leg 126 can have a length L2. In some embodiments, L1 and L2 are approximately the same. In some embodiments, one of L1 and L2 is greater than the other. The length L1 may correspond to the distance L3 between the groove 32 and the end of the corner block 28 and the length L2 may correspond to the distance L4 between the groove 52 and the end of the corner block 50. It is contemplated that, in some embodiments of the invention, corner clips 120 having more than one bend 122 and/or more than two legs 124, 126 may be used. The corner clips 120 illustrated have a first engagement feature 128 configured to be inserted in and engage the groove 32 and a second engagement feature 130 configured to be inserted in and engage the groove 52.

An angle θ between the first leg 124 and the second leg 126 can be greater than about 45° and/or less than about 135° when the corner clip 120 is in a disconnected state (e.g., not engaged with grooves 32, 52). In some embodiments, the angle θ is approximately 75° when the corner clip 120 is in the disconnected state. Preferably, the angle θ between the first and second legs 124, 126 for a given corner clip 120 is less than the angle between the face of the corner blocks 28, 50 having the grooves 32, 52 when abutting. In such cases, the corner clip 120 must be widened (e.g., the angle θ must be increased) in order to fit the corner clip 120 onto the grooves 32, 52. As such, the bending stress in the corner clip 120 due to the widening of the corner clip 120 can bias the first and second engagement features 128, 130 into the grooves 32, 52. Such a biasing force helps the corner clip 120 to stay in place and secure the corner blocks 28, 50 together.

The first and second engagement features 128, 130 can comprise many different and/or alternative means for engaging with the grooves 32, 52. For example, the engagement features 128, 130 can comprise one or more bends at or near the end of the leg 124, 126, respectively, opposite the bend 122. In such embodiments, the engagement features 128, 130 can have a general L-shaped cross-sectional shape. Such an L-shape can be advantageous for a number of reasons. For example, the L-shaped engagement features 128, 130 can help reduce friction between the engagement features 128, 130 and the exterior surface when the corner clip 120 is snapped into place. The engagement features 128, 130 can also have a general U-shaped cross-sectional shape. The U-shape of the engagement feature 128, 130 can flex to facilitate a tight fit of the engagement features 128, 130 within the grooves 32, 52. It is noted that in some embodiments of the invention, including the embodiment illustrated herein, the engagement features 128, 130 may have the same or identical structure, while in other embodiments the engagement features 128, 130 may be dissimilar to each other.

The first leg 124 can also have a raised portion 132 such that a space is formed between the side corner block 28 and the raised portion 132. The raised portion 132 allows for a tool to be inserted into the space to pry the engagement feature 128 out of the groove 32, for disconnection of the corner blocks 28, 50.

As seen in FIG. 4, the knock down bed foundation 10 may also include a fabric cover 140 that is dimension to substantially surround the knock down bed foundation 10. The fabric cover 140 may have an open end such that the knock down bed foundation 10 may be inserted into the open end and a draw string, zipper, or other closure feature may be provided to close the open end of the fabric cover 140. The fabric cover 140 may also have elastic properties so that an open end may be stretched around the knock down bed foundation 10 and retract around the knock down bed foundation 100 to secure the fabric cover 140 in place.

The embodiments of the invention disclosed herein provide for a plurality of benefits including that the side rails 20, end rails 40, center rail 60, set of slats 80, push pin connectors 100 and corner clips 120, when disassembled, may be arranged to fit in a small package to aid in shipping and transporting. Furthermore, by providing corner clips 120 to connect the end rails 40 to the side rails 20, push pin connectors 100 to connect the slats 80 to the side rails 20 and protruding portions 70 on the center rail 60 to be received in openings 48 in the end rails 40, the knock down bed foundation 10 may be assembled and disassembled without the need of tools. This increases the ease of assembly/disassembly, and reduces the burden on the manufacturer or customer to provide or obtain any tools. It is contemplated that the assembly 10 can be made or sold as a kit of components for easy assembly on site by an installer or an end user.

While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible with the scope of the foregoing disclosure and drawings without departing from the spirit of the invention which, is defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 

What is claimed is:
 1. A knock down bed foundation, comprising: a pair of side rails; a pair of end rails extending perpendicularly between the side rails to form corners therewith; a center rail extending perpendicularly between the end rails; a plurality of spaced apart slats extending perpendicularly between the side rails over the center rail; and a plurality of corner clips securing the side rails and end rails together at the corners.
 2. The knock down bed foundation of claim 1, and further comprising a plurality of push pin connectors securing the slats to the side rails.
 3. The knock down bed foundation of claim 2, wherein the side rail member comprises a set of pin apertures disposed therein and receiving the push pin connectors.
 4. The knock down bed foundation of claim 1, wherein the slats comprise pin apertures disposed therein in alignment with the pin apertures of the side rail member and receiving the push pin connectors.
 5. The knock down bed foundation of claim 1, wherein the corners comprise grooves in the side rails and end rails for receiving the corner clips to secure the side rails and end rails together.
 6. The knock down bed foundation of claim 5, wherein the corner clips comprise a first clip leg and a second clip leg joined at a bend, with the clip legs configured to be inserted in and engage one of the grooves.
 7. The knock down bed foundation of claim 6, wherein the at least one of the clip legs comprises a raised portion forming a space between the one of rails forming the corner and the corner clip at the raised portion.
 8. The knock down bed foundation of claim 1, wherein the corners comprise rabbeted corners.
 9. The knock down bed foundation of claim 1, wherein the side rails comprise a recess that receives an end of the end rails for form the rabbeted corners.
 10. The knock down bed foundation of claim 1, wherein the side rails comprise a plurality of notches in an upper side thereof, and the plurality of slats are received within the notches.
 11. The knock down bed foundation of claim 1, wherein the plurality of notches comprise dado notches defined by three sides.
 12. The knock down bed foundation of claim 1, wherein: the side rails comprise an upper horizontal side rail member and a lower horizontal side rail member connected together by vertical side rail members; and the end rails comprise an upper horizontal end rail member and lower horizontal end rail member connected together by vertical end rail members.
 13. The knock down bed foundation of claim 12, wherein opposing ends of the center rail are received between the upper and lower horizontal end rail members.
 14. The knock down bed foundation of claim 13, wherein the center rail comprises an upper horizontal center rail member and lower horizontal center rail member connected together by vertical center rail members.
 15. The knock down bed foundation of claim 1, and further comprising a fabric cover dimensioned to substantially surround the knock down bed foundation.
 16. The knock down bed foundation of claim 1, wherein the corner clips are made from metal, plastic or composite materials.
 17. The knock down bed foundation of claim 16, wherein the side rails, end rails, center rail and slats are formed from a least one of manufactured lumber, plywood, manufactured wood product, or plastic.
 18. A knock down bed foundation kit, comprising: a pair of side rails; a pair of end rails configured to extend perpendicularly between the side rails to form corners therewith; a center rail configured to extend perpendicularly between the end rails; a plurality of slats configured to extend perpendicularly between the side rails over the center rail; and a plurality of corner clips configured to secure the side rails and end rails together at the corners, when the side rails and end rails are positioned perpendicularly with one another.
 19. The knock down bed foundation of claim 18, and further comprising a plurality of push pin connectors configured to secure the slats to the side rails.
 20. The kit of claim 18, and further comprising a fabric cover dimensioned to substantially surround the knock down bed foundation. 